mehalick etal



United States Pattini FA AIR CONDITIONING UNIT CONSTRUCTION John Richard Mehaliek, Fayetteville, and Howard James Tyler, Syracuse, N.Y., assignors to Carrier Corporation, Syracuse, N.Y., a corporation of Delaware Filed Sept. 22, 1958, Ser. No. 762,542

3 Claims. (Cl. 152-429) This invention relates to air conditioning, more particularly to a means for constructing air conditioning units so as to facilitate their manufacture and subsequent maintenance.

The so-called room air conditioner designed for installation in a window or the like wall opening generally comprises a casing containing a refrigeration system including a compressor, condenser and evaporator, all arranged in a closed iiuid circuit through which refrigerant is directed; along with fans for directing air into heat exchange relationship with the condenser and evaporator. These units are generally employed for cooling the air in a conditioned area to thereby lower its temperature and/or its humidity, however, these units may also be employed for heating purposes, by arranging for a heat exchange relationship between the heat dissipating condenser o'f said units and the conditioned area.

The refrigeration system also may require periodic servicing, such as cleaning of the surfaces of the heat exchangers, replenishment of refrigerant, and possible replacement of the compressor-motor assembly. Since size is an important desiderata in the design of an air conditioning unit, all of the elements comprising the unit are generally arranged in as close contines as possible. The close proximity of the assembled elements creates diculties of manufacture and subsequent maintenance because of the relative inaccessibility of the elements. Additionally, where difliculties arise with any one of the elements of an air conditioning unit, it is generally necessary to remove the entire unit from its Window installation and return sameto the shop for servicing. During seasons of peak cooling load, when the unit is most used, and when its services are most required, such servicing is clearly undesirable.

With a view towards eliminating some of the aforementioned problems, the present air conditioning unit construction has been evolved, a construction facilitating the manufacture and subsequent servicing and maintenance of said units by arranging the air handling components, and the refrigeration components of the unit as separable sub-assemblies of the composite unit, so that the sub-assemblies may be readily separated to provide access to any of the components of said sub-assemblies.

1t is accordingly a primary object of this invention to provide an improved air conditioning unit construction facilitating manufacture and maintenance.

Another object of the invention is to provide a novel air conditioning unit in which the components are readily accessible for servicing and/or maintenance.

A further object of the invention is to provide an air conditioning unit in which any defective components in the unit may readily be removed a'nd replaced Without requiring removal of the unit from the conditioned area, and permitting the unit to be rapidly restored to operation.

An additional object of the invention is tol provide an improved compact air conditioning unit construction in which fabrication of the unit is facilitated by providing y 2,959,037 Patented Nov. 8, 1960 nce for a relatively large spacing between the components during fabrication to provide for easy access to and manipulation of said components.

It is an additional object of the invention to provide an improvedl method for forming an air conditioning unit facilitating the manufacture of said unit.

It is also an object of the invention to provide an im proved method for servicing and/or maintaining an air conditioning unit in operative order.

These and other objects of the invention which will become apparent from the following disclosure and claims are achieved by provision of a novel air conditioning unit comprising separate readily conjoinable sub-assemblies, the components of which have a relatively large spacing therebetween, with said sub-assemblies being readily removable from, and replaceable in, the composite unit so as to facilitate manufacture and subsequent maintenance of the unit. A separate refrigeration system sub-assembly is conjoined with an air handling sub-assembly in a readily separable fashion to form a compact unit.

An important feature of the invention resides in the provision of a separate air handling sub-assembly, and a separate refrigerati-on system sub-assembly, in each of which sub-assemblies the components are relatively far apart from each other thus facilitating access to, and manipulation of these components and their securement in the sub-assembly. Thereafter, upon combination of the sub-assemblies into an operative unit subsequent maintenance of the unit is facilitated since either of the sub-assemblies may readily be removed and replaced to maintain the unit in operative condition while the subassembly having a defective component is returned to the shop for repair.

Another important feature of the invention resides in the fact that the air directing surfaces of the unit are formed in a novel fashion and integrally conjoined with a partition panel supporting same. v

An additional feature of the invention resides in the fact that a novel method of manufacture is provided which implements assembly line production techniques in the manufacture of an air conditioning unit.

Another feature of the invention resides in the provision of a novel method for the servicing and maintenance of an air conditioning unit permitting on the site removal and replacement of a sub-assembly containing a defective component whereby the air conditioning unit may be rapidly and efficiently restored to operation.

The specilic structural details of a preferred embodiment of the invention, and their mode of functioning will be made most manifest in full, clear, concise, and exact terms in conjunction with the accompanying drawing, wherein:

Figure 1 represents an exploded perspective view of the air handling sub-assembly and the refrigeration system sub-assembly, said sub-assemblies shown exploded out from each other to reveal their individual components; and

Figure 2 is a perspective view, with parts broken away, looking up at the assembled unit comprising the assembled sub-assemblies, as viewed from the bottom of the condenser side of the unit.

Referring now more particularly to the drawings, like numerals in the various figures will be taken to designate like parts.

As best seen in Figure 1, the air conditioning unit 10 comprises an air handling sub-assembly 11 and a refrigeration system sub-assembly 12.

Air handling system sub-assembly 11 comprises a number of components including a vertically extending heat insulating central partition panel 13 on one side of which is supported a squirrel cage fan scroll 14 having an inlet opening 15 and outlet opening 16 leading to the upper surface of evaporator deck 17 extending outwardly from partition panel 13. Beneath evaporator deck 17, evaporator chamber wall 18 having the configuration shown is provided to form an evaporator chamber and to separate the evaporator from the compressor compartment. On the opposite side of partition panel 13 as best seen in Fig. 2, a condenser chamber is formed by wall 19 of the partition panel within which is condenser fan scroll 21. A condenser scroll deck 22 is extended over scroll 21 and a discharge opening 23 leads upwardly to deck 22. A circular intake opening 24 is formed in the vertically extending wall of scroll 21. Side walls 25 and 26 are arranged respectively along the side edges of the upper surface of evaporator deck 17 and condenser deck 22 respectively to confine the airow into a desired pattern. Discharge louvres 27 are supported between sidewalls 25 and 26 to direct the condenser air stream away from condenser deck 22. Supported on a mounting bracket, not shown, secured to partition panel 13 is fan motor 29 on the condenser side of the partition panel. A squirrel cage evaporator fan 30 is arranged Within evaporator fan scroll 14, and a draw-through propeller type condenser fan 31 is arranged within condenser fan scroll 21, both fans driven by the fan motor. As seen in Figure 2 a slinger ring 33 is arranged about the periphery of condenser fan 31.

Refrigeration system sub-assembly 12 comprises a base pan 35 having upstanding peripheral flanges 36 extending thereabout. Secured by appropriate means to base pan 35 is an evaporator 37 formed in a conventional fashion of parallel runs of tubing connected by return bends, with said runs of tubing provided with n plates for extending the effective heat transfer surface thereof. A condenser coil 3S similarly formed is secured on the opposite side of base pan 35, and a sealed motor driven compressor 39 is mounted on the base pan 35 approximately centered with respect to the evaporator 37 and condenser 38 for a purpose to become hereinafter more apparent. The compressor 39, condenser 3S, and evaporator 37 are connected by appropriate tubing (not shown) to form a closed compression refrigeration circuit. Appropriate electrical wiring for control purposes is also provided.

The afore-described sub-assemblies 11 and 12 after manufacture, and/or servicing, are assembled into the unit assembly illustrated in Figure 2 by lowering air handling sub-assembly 11 downwardly on the normally heavier refrigeration sub-assembly. In this assembled relationship, it will be observed that the components of the assembled sub-assemblies nest between each other to form a compact unit with condenser 38 lying on one side of partition panel 13 and evaporator 37 lying on the opposite side thereof. It will also be observed in Figure 2 that the compressor 39 is shielded from the evaporator by means of walls 1S, 19, and 19 and is shielded from the condenser by means of walls 19 and 19".

In use, the afore-dsclosed constructional features serve to facilitate production of air conditioning unit 10, and to implement its subsequent servicing and maintenance. In manufacture the structural components of the air handling sub-assembly 11 are fabricated of a sheet metal material, note partition panel 13, and molded plastic material, for example, expanded polyethylene, note the lfan scrolls. Assembly of the components of air handling sub-assembly 11 is accomplished by securing fan motor mounting bracket (not shown) to the panel 13, and mounting the fan motor 29 thereon. Thereafter the molded fan scrolls, decks, and walls are secured to the partition panel; and squirrel cage fan 30 and condenser fan 31 are secured to the fan motor drive shaft by suitable connecting means on opposite sides of the partition panel as seen. The sequence of assembly can be changed depending upon the size of the fans. It will be observed that the assembly of the afore-mentioned components is relatively simple, since access to the components is facilitated by the spacing provided therebetween.

Fabrication of the refrigeration system sub-assembly 12 is similarly implemented by the relatively large spacing between the sub-assembly components. Thus, compressor 39 is bolted to base pan 35, along with evaporator 37 and condenser 38. Suitable fastening means (not shown) are employed for securing the compressor, evaporator, and condenser to the base pan. The position of compressor 35 is such that the center of gravity of the compressor is substantially coplanar with the center of gravity of the evaporator and condenser, to thereby provide a substantially weight balanced unit.

Conjoining of the sub-assemblies is accomplished by lowering the air handling sub-assembly 11 over the refrigeration system sub-assembly 12 with the components of the sub-assemblies nesting between each other to form a compact unit 11). After assembly of the sub-assemblies 11 and 12 into unit 10 the unit 11i is enclosed in an appropriate casing 40, and the unit 10 installed in a window or the like wall opening of the area to be conditioned.

When during the course of operation, maintenance or servicing are required, the unit 1i) is removed from the casing, and the sub-assembly having the `defective component separated from the assembled unit 1d, and replaced by a replacement sub-assembly, while the defective sub-assembly may be removed to the shop for repair, thus substantially minimizing the down-time of the unit.

It is thus seen that a novel mode of construction in which air conditioning units are fabricated in the `form of separable and replaceable sub-assemblies has been provided, which facilitates production by providing for ready accessibility of the components during production, and further simplifies servicing and maintenance, and reduces down-time by permitting removal and replacement of any defective components at the site of the unit.

The above disclosure has been given by way of illustration and elucidation, and not by way of limitation, and it is desired to protect all embodiments of the herein disclosed inventive concept within the scope of the appended claims.

We claim:

1. An air handling system sub-assembly for use in an air conditioning unit, said sub-assembly comprising a partition panel adapted to divide said unit into a condenser compartment and an evaporator compartment; a fan motor mounted on said panel; a condenser fan and an evaporator fan secured to said motor on opposite sides of said panel; a condenser fan scroll secured to said panel over said condenser fan; an evaporator fan scroll secured to said panel over said evaporator fan; a condenser fan scroll deck secured to said panel over the condenser scroll; a condenser chamber wall secured to said panel beneath said deck; an evaporator fan scroll desk secured to said panel over said evaporator scroll; and an evaporator chamber wall secured to said panel beneath said evaporator scroll deck.

2. An air conditioning unit comprising in combination a refrigeration system sub-assembly and an air handling system sub-assembly for directing air into heat exchange relationship with the refrigeration system, said sub-assemblies adapted to be enclosed by a casing; said refrigeration system sub-assembly including as components a base plate, a condenser and an evaporator secured `on said plate adjacent opposite edges to form a relatively open central space on the plate, and a compressor secured on said plate adjacent a side thereof; said air handling subassembly including as components a partition panel having a generally U-shaped portion on an end thereof, a motor mounted on said panel, and a condenser -fan and an evaporator fan operatively connected to said motor on opposite sides of said panel, said air handling subassembly removably conjoined with said refrigeration system sub-assembly into a compact operative Iunit with said air handling sub-assembly nesting in said open central space, said partition panel dividing said unit into a condenser compartment, an evaporator compartment and a compressor compartment, whereby prior to conjoining of said sub-assemblies, the components thereon will be readily accessible to facilitate manufacture and maintenance.

3. An air conditioning unit as in claim 2 comprising a condenser fan scroll secured to said panel over said motor, a condenser fan scroll deck secured to said panel over the condenser scroll, an evaporator fan scroll secured to said panel on a side thereof opposite said condenser fan scroll, and an evaporator fan scroll deck secured to said panel over said evaporator fan scroll.

References Cited in the le of this patent UNITED STATES PATENTS 2,023,876 Dubrovn Dec. 10, 1935 2,405,411 Dybvig Aug. 6, 1946 2,711,087 Jennings June 21, 1955 2,730,873 Hardin Ian. 17, 1956 2,736,176 Carlton Feb. 28, 1956 2,769,320 Kyhkebschmidt Nov. 6, 1956 2,793,510 Komro May 28, 1957 2,824,429 Zucker Feb. 25, 1958 

